Installation and Service Instructions HD Series Pumps Industrial Duty Models

Service Instruction No.
71
INSTALLATION AND SERVICE

INSTRUCTIONS
HD SERIES PUMPS
INDUSTRIAL DUTY MODELS
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WARNING WARNING
Read Manual before operating or working on a Tuthill HD pump.
Table Of Contents
Page 3: Introduction
Page 4: General Description / Pumping Principle / HD Models
Page 5: HD Model Numbering System
Page 6: Temperature Limits
Page 7: Installation
Page 8: Packing Adjustments
Page 9: Lubrication Requirements / Recommended Lubricants
Page 10: Inspection and Repair
Page 11: Parts Diagram (30A, 2A, 3A, 70A, 120A & 330 Pumps)
Page 12: General Parts List (30A, 2A, 3A, 70A, 120A & 330 Pumps)
Page 13: Parts Diagram (O5 Series Model 70A, 120A & 330 Pumps)
Page 14: General Parts List (O5 Series Model 70A, 120A & 330 Pumps)
Page 15: Parts Diagram (O5 Series Model 70A, 120A & 330 Pumps with Tuffseals)
Page 16: General Parts List (O5 Series Model 70A, 120A & 330 Pumps with Tuffseals)
Page 17: Parts Diagram (O5 Series Model 70A, 120A & 330 Pumps with Mechanical Seals)
Page 18: General Parts List (O5 Series Model 70A, 120A & 330 Pumps with Mechanical Seals)
Page 19-20: Minor Disassembly Instructions (30A, 2A, 3A, 70A, 120A & 330 Pumps)
Page 21: Minor Assembly Instructions (30A, 2A, 3A, 70A, 120A & 330 Pumps)
Page 22: Major Disassembly Instructions (30A, 2A, 3A, 70A, 120A & 330 Pumps)
Page 23: Major Assembly Instructions (30A, 2A, 3A, 70A, 120A & 330 Pumps)
Page 24: Pump Clearances (30A, 2A, 3A, 70A, 120A & 330 Pumps)
Page 25: Parts Diagram (Model 600 Pump)
Page 26 General Parts List (Model 600 Pump)
Page 27: Parts Diagram (O5 Series Model 600 Pump)
Page 28: General Parts List (O5 Series Model 600 Pump)
Page 29: Parts Diagram (O5 Series Model 600 Pump with Tuffseals)
Page 30: General Parts List (O5 Series Model 600 Pump with Tuffseals)
Page 31: Parts Diagram (O5 Series Model 600 Pump with Mechanical Seals)
Page 32: General Parts List (O5 Series Model 600 Pump with Mechanical Seals)
Page 33-34: Minor Disassembly Instructions (Model 600 Pump)
Page 35: Minor Assembly Instructions (Model 600 Pump)
Page 36-37: Major Disassembly Instructions / Major Assembly Instructions (Model 600 Pump)
Page 38: Pump Clearances (Model 600 Pump)
Page 39-40: Packing Section
Page 40: General Tuffseal Installation
Page 41; General Mechanical Seal Installation
Page 42: Torque Specifications For Shaft Locknuts & Faceplate Bolts
Page 43: Serial Number Location
Page 44: Common Pump Problems
Page 45: Troubleshooting
Page 46: Material Returns / Warranty / Contact Information
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Introduction
The HD Series pumps have been certified to the requirements of the ATEX Directive 94/9/EC for
use in Category II, Group 2 G applications. Read this manual before operating or working on the HD
Series pumps. If additional information is required to facilitate operation or maintenance, contact the
authorized Tuthill distributor shown at the back of this service manual.
HD Series pumps have been designed and manufactured to provide years of service under
normal operating conditions.
Illustrations used in this manual are for reference purposes only. Consult the factory or an
authorized Tuthill distributor for proper part identification.
When ordering replacement parts, provide as much detail as possible to ensure correct parts are
provided. Details should include the full model number (typically 12-13 digits but can be 18 digits), serial
number, name of part, part number (if known), and part material.
Service Manual # 71 for the HD Series pumps is available at www.tuthillpump.com
The materials furnished for each pump are selected to suit individual applications.
WARNING WARNING
Failure to follow these instructions could result in serious bodily injury or death.
Do not attempt to work on any Tuthill pump installation before completing the steps below.
Disconnect the drive so that it cannot be started while work is being performed.
Review the Material Safety Data Sheet (MSDS) applicable to the liquid being pumped to determine
its characteristics and the precautions necessary to ensure safe handling.
Vent all pressure within the pump through the suction or discharge lines.
All Tuthill pumps contain residual hydraulic oil from the factory production test.
Determine if this is compatible with the fluid you are pumping. If the fluid is incompatible, then the pump
must be fully flushed prior to use.
If the pump is to be operated at elevated temperatures, the pump should be brought up to operating
temperatures gradually. Rapid or sudden introduction of liquids at elevated temperatures into the cold
liquid chamber of the pump could cause damage to pump externals, seals or other internal parts.
Pumps can run dry provided provisions are made for the mechanical seal if one is used. Failure to
comply with this could cause severe damage to the mechanical seal parts.
Pump needs to be earthed separately to avoid a buildup of electro-static charge.
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General Description
The design of the Tuthill Industrial Series incorporates externally timed impellers that are
supported in the fluid chamber by double row, ball bearings located out of the product stream. This
design enables the industrial Series to handle highly viscous abrasive slurries, corrosive acids or
suspended solids without degradation, aeration or contamination of the product.
PUMPING PRINCIPLE:
Here’s how it works:

Rotating impellers develop a vacuum at inlet, drawing material into the cavity…positive action of the
impellers displaces material, forcing discharge at pump outlet. Ports are always open; sealing action
between impellers and housing prevents fluid flow return.
HD Models
Material of Max. Max. Capacity Max. Pressure Weight Port Size

Size
Construction Speed USGPM LPM PSI BAR LB KG (Internal NPT)
1-1/2‖ Top
30A 450 24.7 93 150 10.3 100 45
1-1/2‖ Front
2‖ Top
2A 450 67.5 256 150 10.3 250 113
2‖ Front
3‖ Top
3A 450 135 511 150 10.3 270 122
3‖ Front
3‖ Top
Ductile Iron 70A 450 67.5 256 450 27.5 280 127
2‖ Front
4‖ Top
120A 450 135 511 450 27.5 300 136
3‖ Front
5‖ Top
330 450 337 1276 450 27.5 550 249
4‖ Front
6‖ Right
600 450 666 2523 450 27.5 900 408
6‖ Left
30A 450 24.7 93 150 10.3 100 45 Same As Above

2A 450 67.5 256 150 10.3 250 113 Same As Above
3A 450 135 511 150 10.3 270 122 Same As Above
Stainless
70A 450 67.5 256 450 27.5 280 127 Same As Above
Steel
120A 450 135 511 450 27.5 300 136 Same As Above
330 450 337 1276 450 27.5 550 249 Same As Above
600 450 666 2523 450 27.5 900 408 Same As Above
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HD PROCESS PUMP NUMBERING SYSTEM
1 2 3 4 5 6 7 8 9 10 11 12 13
O5 – INDUSTRIAL O2-STANDARD DUTY O4-STANDARD DUTY

O1-INDUSTRIAL
DIGITS 1 & 2 DUTY (ID) (SD) (SD)
DUTY (ID)
Only Models with ** Ductile Iron Only Stainless Steel Only
05 – Model 30
01 – Model 5A
14 – Model 2A
02 – Model 10
16 – Model 70A**
03 – Model 16
DIGITS 3 & 4 29 – Model 3A
05 – Model 25A
31 – Model 120A**
14 – Model 65
75 – Model 330**
26 – Model 125A
91 – Model 600**
04 – 316 Stainless Steel (O1, O4 & O5 Models)

DIGITS 5 & 6
09 – Ductile Iron (O1, O2 & O5 Models)
0 – Internal NPT (Std. on ID models)
DIGIT 7
1 – External NPT (Standard on SD models)
0 – No Relief Valve
DIGIT 8
1 – Relief Valve (Available on all SD models & ID models 30, 2A, 3A, 70A, 120A)
01 – Hot Clearance
02 – Special Shaft Material
05 – Special Packing
06 – Special Packing Configuration
08 – Mechanical Seals
09 – Special Bushings
DIGITS 9 & 10 10 – Special Clearances
13 – Steam Jacket/Tracing
19 – Special Ports (Flanged, etc.)
21 – Tutriding
26 – Interference Fit Gears
27 – Special U-Cup/Lip Seals
28 - Miscellaneous
DIGITS 11 & 12 01, 02, Etc. (Serialized at the factory)
DIGIT 13 D – Double Lobe (Available on ID models only)
(If Required) T – PTFE housing and faceplate bushings (SD Models)
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-50 °F
250 °F
300 °F
350 °F
400 °F
450 °F
500 °F
550 °F
600 °F
-100 °F
0 °F
50 °F
100 °F
150 °F
200 °F
-
-
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Note:
Standard Pump Materials
Class 1 Clearance Impellers
High Temp. Carbon Bushings

Standard Carbon Bushings in S.S. Pumps
in S.S. Pumps
PTFE-Glass Filled
Standard Gasket Material
Gaskets
Gore-Tex Rope Gaskets
Viton Oil Seals for Faceplate

Standard Oil Seals for Faceplate and Gear Case
and Gear Case
PTFE Oil Seals for Faceplate
Page 6 of 46
Standard Oil Seals for Faceplate and Gear Case
and Gear Case
High Temperature APG 250

Standard Gear Case Oil
Gear Case Oil
Standard DU Bushings for Ductile Iron Pumps
Carbon Bushings
Viton and PTFE oil seals can be used in place of standard oil seals upon request.
Bronze Bushings for Ductile Iron Pumps Used in Ductile Iron
PTFE and Gore-Tex gaskets can be used in place of standard seals upon request.
TEMPERATURE LIMITS OF HD PROCESS PUMP MATERIALS
Pumps
6.10.08
Standard Packing
WARNING WARNING
Installation
For optimum pump performance the suction line must be at least as large as the corresponding
pump port. It should be as short as possible in order to avoid excessive pressure drops and must be
airtight. Locate the pump as close to the source of supply as conditions permit, and if possible, below the
level of the liquid in the reservoir. When necessary to locate the pump in a pit, provisions should be made
to safeguard against flooding.
When handling high viscosity liquids, the speed of the pump must be reduced and the size of the
inlet lines increased to prevent cavitation. Refer to the NPSHr data for the pump.
Pumps should be filled with liquid at installation.
The placement of a strainer on the suction side of the pump will restrict any solids or abrasives
from entering the pump, which could cause internal damage.
Under no conditions should the pump be used to support external piping loads (weight or
expansion). Piping and other equipment should be independently supported. Piping strain can result in
misalignment, hot bearings, worn couplings, vibration, etc. It is important that the piping used be clean
and free of chips and scales.
The discharge line must be designed with the maximum pressure rating of the pump in mind.
Excessive pressure could cause damage to your motor and/or pump. If a pressure relief valve has not
been supplied with the pump, some other means of pressure protection must be utilized. This could
include in-line safety valves, pressure shutdown switches or other similar devices.
Pumps are positive displacement pumps and must be used in conjunction with a pressure relief
mechanism.
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Every pump installation should have a good foundation. Its structure should be sufficiently strong
to hold the pump rigid and to absorb any strain or shock that may be encountered. The installation should
be leveled, checked for proper piping alignment, and then fastened securely. The alignment should be
rechecked after the pump’s temperature has reached its operating temperature.
Direct drive through a traditional flexible coupling is recommended. However, do not expect the
coupling to compensate for misalignment. Contact the coupling manufacturer to determine the maximum
amount of misalignment that the coupling can be subjected to.
Never operate the pumps without all the guards in place.
Direction of Flow:
Tuthill Industrial Process Pumps may be operated in either direction. The direction of flow is
dependent on the direction of rotation of the pump drive shaft. When facing the drive shaft of the pump, a
clockwise rotation provides a top suction port and a bottom discharge port. This applies to Model 30A,
2A, 3A, 70A, 120A, 330 Pumps (Pages 11, 13, 15 & 17).
Model 600 Pumps are equipped with a vertical shaft arrangement (Page 25, 27, 29 & 31). On these
models a clockwise drive shaft rotation will provide a left hand suction port and a right hand discharge
port. Flow would be from left to right when facing the drive shaft.
Packing Adjustment
WARNING WARNING
Packing is designed to leak. Therefore, when pumping hazardous liquids, a mechanical seal is
recommended to minimize any potential source of leakage that could result in a hazardous condition.
All packings must leak to perform properly. Their purpose is to control leakage—not to prevent it.
The slight leakage along the shaft provides proper lubrication to the packing. Pump packings
have a lubricant, which acts as a primary sealant for the start-up and break-in phases, during which this
lubricant acts to reduce friction. Once the pump is on the line, external lubrication must be supplied to the
packing to keep it running properly and to attain longer life. If external lubrication is not supplied, the
lubrication in the packings will bleed out due to heat generation. Heat is a primary cause of packing
failure.
Pumps with packing will require periodic adjustment.
To accomplish this, gently and evenly tighten the packing gland nuts, which will further compress
the packing. Do not over-tighten. Packing is designed to keep leakage to a slight weep. Normally 2-3
drops per minute is acceptable.
If excessive leakage persists after complete adjustment, consider re-packing the stuffing box or
using another packing type.
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Lubrication Requirements
Faceplate Bearings:
The faceplate bearings are greased. Grease should be added to faceplate bearings when oil is
changed. Add grease through fitting until new grease can be seen exiting under lip seal where shaft
enters bearing. Bearings are designed to provide a minimum L10 life of 15,000 hours at maximum speed
and pressures conditions.
Housing Bushing:
Housing bushings are fully lubricated by the pumped fluid and are maintenance free.
Gear Case Bearings:
Bearings are designed to provide a minimum L10 life of 15,000 hours at maximum speed and
pressures conditions and are splashed lubricated.
Lubrication Instructions For Tuthill Process Pumps
The oil used in the gear case of the process pumps is ―Lubriplate‖ APG9. Lubriplate is a trade
name of Fiske Brothers Refining Company – Toledo, Ohio.
Oil specifications are as follow:
Viscosity at 100F: 816 SSU Viscosity at 212F: 86 SSU

API Gravity: 26.5 Flash Point: 39F
Fire Point: 440F Extreme Pressure Additives
Any 90-weight gear oil may be substituted if equivalent to above.
The grease used in the faceplate ball bearing of the Industrial Series pump is ―Lubriplate‖ 1200-2.
Grease specifications are as follows:
Lithium Base N.L.G.I. #2

Work Penetration: 280 A.S.T.M. Dropping Point: 450F
Minimum Oil Viscosity at 100F: 950SSU
Water resistant with rust and corrosion inhibitors added.
Any #2 bearing grease may be substituted if equivalent to above.
The following charts on lubrication requirements are offered as a guide only. Common sense
approach to preventative maintenance must be exercised for best pump service life. Ambient conditions
(temperature, humidity, dust, etc.) can alter schedule:
Gearcase First Oil Subsequent Total Grease Capacity

Model No. Capacity - CC Change – Hrs. Change – Hrs. Per Pump - CC
30A 500 500 3000 30
2A & 3A 1900 500 3000 35
70A & 120A 250 500 3000 165
330 1000 500 3000 140
600 1250 500 3000 100
Above standard lubricants are adequate for operating temperatures between –100°F and +350°F.
If temperature exceeds 350°F, use the following:
Oil Specification: Lubriplate APG 250 or equal

Bearing Grease: 930-AA or equal
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Inspection and Repair
Should it be necessary to remove the pump from service for periodic inspection of components
and/or a major repair, the following steps should be taken. See following pages for exploded pump views
and instructions.
WARNING WARNING
Only authorized personnel who are familiar with the repair of mechanical products should perform the
necessary repair work. You must familiarize yourself with the entire contents of this manual prior to
performing any work.
Ensure that the pump has cooled to a safe temperature prior to performing any work on the pump.
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General Parts List For 30A, 2A, 3A, 70A, 120A, and 330 Pumps (Models Starting w/ O1)
Item # Description Qty Item # Description Qty

1 Dowel Pin 4 22 Faceplate (CI) 1
2 Cap Screw 2 (SS)
3 Square Key 1 23 Hex Head Bolt *
4 Timing Gears 2 24 Pipe Plug (CI) 8
5 Driven Shaft (CI) 1 (SS)
(SS) 25 V-Ring 4
6 Gear Key 2 26 Housing Gasket 1
7 Cap Screw * 27 Impeller Housing (CI) 1
8 Impeller Key (CI) 2 (SS)
(SS) 28 Housing Bushings 2
9 Impellers (CI) S.L. 2 (CI) DU Bushing
(CI) D.L. (SS) Carbon Bushing
(SS) S.L. 29 Packing 4 sets
(SS) D.L. 30 Packing Gland (CI) 4
10 Drive Shaft (CI) 1 Split Glands for (SS) 8
(SS) 31 Stud 8
11 Set Screw (CI) 4 32 Nut (CI) 8
(SS) (SS)
12 Hex Head Bolt 6 33 Lip Seal 3
13 Grease Fitting 2 34 Spacer 2
14 Bearing Cover 2 35 Roller Bearing 2
15 Lock Nut 2 36 Cap Screw 2
16 Lock Washer 2 37 Bearing Housing 1
17 Ball Bearing 2 38 Pipe Plug (CI) 2
18 Lip Seal 2 (SS)
19 Bearing Carrier 2 39 Gear Case Gasket 1
20 Set Screw * 40 Gear Case Cover 1
21 Shim ----------.002‖ As Req. 41 Cap Screw 6
.005‖ As Req. 42 Vented Pipe Plug 1
.015‖ As Req. 43 Nametag 1
44 Drive Screw 2
Note:
- * Exact quantities will vary depending upon actual pump model.
- (CI) are Cast Iron pumps that will have corresponding steel and/or ductile iron components.
- (SS) are Stainless Steel pumps that will have corresponding stainless steel components.
- Recommended spare parts are in bold text.
- When ordering spare parts please specify pump model, serial number, part number & part name.
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General Parts List For 70A, 120A, and 330 Pumps (Models Starting w/ O5)

2 Cap Screw 2 (SS)
5 Driven Shaft 1 (SS)
(Armco 17-4PH) 25 V-Ring 4
6 Gear Key 2 26 Gore-Tex Gasket 1
(SS) S.L. 29 Packing 4 sets
(SS) D.L. 30 Packing Gland (CI) 4
10 Drive Shaft 1 Split Glands for (SS) 8
(Armco 17-4PH) 31 Stud 8
11 Set Screw (CI) 4 32 Nut (CI) 8
(SS) (SS)
12 Hex Head Bolt 6 33 Lip Seal 3
13 Grease Fitting 2 34 Spacer 2
14 Bearing Cover 2 35 Roller Bearing 2
15 Lock Nut 2 36 Cap Screw 2
16 Lock Washer 2 37 Bearing Housing 1
17 Ball Bearing 2 38 Pipe Plug (CI) 2
18 Lip Seal 2 (SS)
19 Bearing Carrier 2 39 Gear Case Gasket 1
20 Set Screw * 40 Gear Case Cover 1
21 Shim ----------.002‖ As Req. 41 Cap Screw 6
.005‖ As Req. 42 Vented Pipe Plug 1
.015‖ As Req. 43 Nametag 1
44 Drive Screw 2
Note:
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General Parts List For 70A, 120A, and 330 Pumps (Models Starting w/ O5 & Tuffseals)

2 Cap Screw 2 (SS)
5 Driven Shaft 1 (SS)
(Armco 17-4PH) 25 V-Ring 4
6 Gear Key 2 26 Gore-Tex Gasket 1
(SS) S.L. 29 Tuffseal 4
(SS) D.L. 31 Stud 8
10 Drive Shaft 1 32 Nut (CI) 8
(Armco 17-4PH) (SS)
11 Set Screw (CI) 4 33 Lip Seal 3
(SS) 34 Spacer 2
12 Hex Head Bolt 6 35 Roller Bearing 2
13 Grease Fitting 2 36 Cap Screw 2
14 Bearing Cover 2 37 Bearing Housing 1
15 Lock Nut 2 38 Pipe Plug (CI) 2
16 Lock Washer 2 (SS)
17 Ball Bearing 2 39 Gear Case Gasket 1
18 Lip Seal 2 40 Gear Case Cover 1
19 Bearing Carrier 2 41 Cap Screw 6
20 Set Screw * 42 Vented Pipe Plug 1
21 Shim ----------.002‖ As Req. 43 Nametag 1
.005‖ As Req. 44 Drive Screw 2
.015‖ As Req. 45 Washer 8
Note:
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General Parts List For 70A, 120A, and 330 Pumps (Models Starting w/ O5 & Mech. Seals)

1 Dowel Pin 4 23 Hex Head Bolt *
2 Cap Screw 2 24 Pipe Plug (CI) 8
3 Square Key 1 (SS)
4 Timing Gears 2 25 V-Ring 4
5 Driven Shaft 1 26 Gore-Tex Gasket 1
(Armco 17-4PH) 27 Impeller Housing (CI) 1
6 Gear Key 2 (SS)
7 Cap Screw * 28 Housing Bushings 2
8 Impeller Key (CI) 2 (CI) DU Bushing
(SS) (SS) Carbon Bushing
9 Impellers (CI) S.L. 2 29 Mechanical Seal 4
(CI) D.L. 30 Mech. Seal Gland (CI) 4
(SS) S.L. (SS) 4
(SS) D.L. 31 Stud 8
10 Drive Shaft 1 32 Nut (CI) 8
(Armco 17-4PH) (SS)
11 Set Screw (CI) 4 33 Lip Seal 3
(SS) 34 Spacer 2
12 Hex Head Bolt 6 35 Roller Bearing 2
13 Grease Fitting 2 36 Cap Screw 2
14 Bearing Cover 2 37 Bearing Housing 1
15 Lock Nut 2 38 Pipe Plug (CI) 2
16 Lock Washer 2 (SS)
17 Ball Bearing 2 39 Gear Case Gasket 1
18 Lip Seal 2 40 Gear Case Cover 1
19 Bearing Carrier 2 41 Cap Screw 6
20 Set Screw * 42 Vented Pipe Plug 1
21 Shim ----------.002‖ As Req. 43 Nametag 1
.005‖ As Req. 44 Drive Screw 2
.015‖ As Req. 45 Seal Gland Gasket 4
22 Faceplate (CI) 1
(SS)
Note:
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Disassembly & Reassembly Instructions for 30A, 2A, 3A, 70A, 120A, & 330 Pumps
Minor Disassembly For Fluid Chamber Inspection:
1. Remove all burrs on drive shaft with a file or emery paper. Also check for any deposit of paint.
Special care should be taken around the keyway and beveled corner on the drive shaft. These
two areas are normally where burrs occur. Burrs or paint will cause an obstruction in the bushing
area.
2. Drain oil from gear case by removing lower drain plug (38). Remove six cap screws (41) on face
of gear case cover (40).
3. Remove gear case cover by sliding over shafts.
4. If the timing gears (4) are a slip fit on the shafts. Check that the gears have the correct timing
marks before removal. If necessary, mark them again. Remove the gears by loosening the
setscrews. There are two in each gear. Then slide gears off drive end of shaft. If gear keys are
sheared a gear puller may be required. NOTE: Mark gears so that in reassembly the gears may
be remounted on the shafts from which they were removed. Remove two gear keys.(6)
5. If interference fitted (IF) timing gears (4) are furnished. Check that the gears have the correct
timing marks before removal. If necessary, mark them again. IF gears do not have setscrews.
First attempt to remove them can be can be made with a standard gear puller. If the gear puller
was not successful in removing the gears, heat the gear OD with a torch and use a hydraulic jack
to remove the gears. NOTE: Mark gears so that in reassembly the gears may be remounted on
the shafts from which they were removed. Remove two gear keys.(6)
WARNING WARNING
Wear heat-resistant gloves when handling hot components.
6a. If Packing is used (reference assembly on page 13):

i. Remove packing gland nuts (32) and slide packing gland (30) out of the way. Then remove
packing (29) from both seal chambers in the impeller housing. If pump is equipped with
mechanical seals, see below for general instructions and refer to the seal instructions that
were shipped with the pump. Also, reference Page 39 for additional packing information.
6b. If Tuffseals are used (reference assembly on page 15):
i. Loosen Tuffseal set screws that lock the cartridge seal’s collar onto the shaft, on the impeller
housing side. Also, reference Page 40 for additional Tuffseal information.
6c. If mechanical seals are used (reference assembly on page 17):
i. Remove pipe plugs (24) from impeller housing stuffing boxes. This allows access to the
mechanical seal set screws holding the seal to the shaft. Mark the shaft where the
mechanical seal is so that the correct seal working length can be referenced upon re-
assembly. Then loosen the mechanical seal set screws.
ii. Loosen the mechanical seal gland nuts (32) and allow the mechanical seal gland to be loose
on the housing. Thus, when the shafts are pulled out of this area when removing the
faceplate assembly the gland will not fall off. Allow it to hang loosely on the studs. Also,
reference Page 41 for additional mechanical seal information.
7. Remove hex head bolts (23) on outboard side of faceplate. Make note on which side the drive
shaft is located for reassembly. Remove entire faceplate assembly by sliding away from impeller
housing. CAUTION: Faceplate assembly will be heavy and not balanced. Use proper lifting
methods. This assembly includes the impellers and shafts installed in the faceplate. CAUTION:
DO NOT DISTURB the bearing carrier (19) on the bearing bridge on the faceplate. These caps
hold the adjustment of the clearance of the impellers in relation to the fluid chamber.
If further disassembly is required, refer to major disassembly instructions.
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Fluid Chamber Check Points:
Procedure No. 1 - Check for twisted shaft
1. Place faceplate group upright in vise.

Caution: Use soft jaws to prevent damage to the gasket seal surfaces. Tighten jaws on sides of
bearing bridge.
2. Install carbon steel gear keys on an angle. Angle is to hold gears from sliding down on shaft.
3. Slide proper timing gear on drive shaft, revolving shaft to align key with gear keyway, taking
precautions that the timing marks are face out and aligned. There are two punch marks
appearing on the gear on the drive shaft and one punch mark on the mating tooth on the driven
shaft.
4. Turn impellers to the position shown below. If the dimension X is the same as dimension Y, then
there is no shaft damage. If there is a variation, then the shaft is twisted or the impeller keys may
be sheared. Disassemble in accordance with major disassembly instructions. If the impeller keys
are sheared, then install new keys and recheck for twisted shaft.
Procedure No. 2 - Install new gears
1. Place faceplate group in vise and install keys as in Procedure No. 1.

2. Slide gear on driven shaft, aligning keyway of gear with woodruff key on shaft.
3. Position impellers as shown in the sketch in Procedure No. 1 with dimension X the same as
dimension Y.
4. Slide timing gear on drive shaft and align keyway in gear with woodruff key in shaft and mesh
gears.
5. Recheck dimension X and dimension Y to be certain that they are the same.
6. Mark gears as indicated in Procedure No. 1.
7. Slide gears off shafts and follow minor reassembly instructions.
Procedure No. 3 - Install new bushings
1. Disassemble in accordance with minor disassembly instructions.

2. Press worn bushing from impeller housing and gear case.
3. Press new bushings in impeller housing.
4. Press bronze bushings in gear case.
5. Remove expansion plug in gear case cover.
6. Press out worn bushings and press new bushings in gear case cover. Caution: If impeller housing
bushing is steel backed PTFE, do not ream.
7. Check gearcase lip seals and bearings for damage. Replace parts as necessary.
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Reassemble In Accordance With Minor Reassembly Instructions:
1. Apply grease to gasket seal surface on impeller housing. Then press gasket in place. Grease is
used to hold gasket in position.
i. Place packing glands in seal chambers in housing. Also, reference Page 39 for additional
packing information.
i. Make sure the Tuffseal on the impeller housing side is ready to accept the shafts and that the
collar set screws are unscrewed enough so that the shafts can slide through the collars
easily. Also, reference Page 40 for additional Tuffseal information.
i. Make sure the mechanical seal bodies in the impeller housing stuffing boxes are ready to
accept the shafts and that the seal set screws are unscrewed enough so that the shafts can
slide through the seals easily. Also, reference Page 41 for additional mechanical seal
information.
3. After checking for burrs, insert shafts through housing bushing, packing glands/mechanical
seals/Tuffseals and gear case bushings. V-rings should also be installed while inserting the
shafts. Be aware that the V-rings need to be slid onto the shafts because of their snug fit.
Note: Insert drive shaft in the same position as when disassembled.
4. Tighten cap screws, which hold the faceplate in place.
5. Install carbon steel gear keys in shaft keyways.
6. Slip proper timing gear on driven shaft.
7. Slip timing gear on the drive shaft, rotating shaft to align key with gear keyway, taking precautions
that the timing marks are face out and aligned. There are two punch marks appearing on the
gear on the drive shaft and one punch mark on the mating tooth on the driven shaft.
8. Spin the pump drive shaft several times to be certain that there is no interference from incorrect
timing.
9. Apply grease to gasket seal surface on gear case. Press gasket in place. The same gasket is
used on both impeller housing and gear case.
10. Slide gear case cover over shafts, being certain that drive shaft bore in cover is properly
positioned in relation to drive shaft.
CAUTION: Take care in sliding lip of oil seal over drive shaft. If proper care is not taken, the lip
will be damaged and oil leakage will result.
11. Tighten six cap screws holding gear case cover in place.
i. Install new packing in seal chambers and tighten packing gland nuts to finger tightness. If
pump is equipped with mechanical seals, install them according to the seal instructions and
reference 12c for general instructions. Also, reference Page 39 for additional packing
information.
i. Use the seal spacers to set the right collar location. After setting the end clearances, tighten
the gland nuts and then collar set screws to lock the seal collar onto the shaft. Finally, turn
the spacers away from the collar so they will not interfere with it during operation. Also,
reference Page 40 for additional Tuffseal information.
i. Position the mechanical seal body axially on the shaft using the previous mark that was made
during disassembly.
ii. After setting the end clearances, tighten the seal set screws to the shaft.
iii. Install the mechanical seal gland back into the impeller housing stuffing box and tighten the
gland nuts (32). Re-install the pipe plugs (24). Also, reference Page 41 for additional
mechanical seal information.
13. Install the drainpipe plug.
14. Remove oil level plug and fill gear case with lube oil (see lube oil chart, page 9) to the oil level
hole.
15. Install and tighten fill plug and oil level plug.
16. Spin the assembled pump several times to be certain that there is no interference from incorrect
timing. If no interference is apparent, then the pump is ready to be put back in service.
v 1.5 Page 21 of 46 6.10.08

Major Disassembly Instructions:
The first seven steps are the same as in the minor disassembly procedure. The major disassembly
involves the disassembly of the faceplate group.
8. Place faceplate group in a vise.

CAUTION: Use soft vise jaws to prevent damage to gasket seal surface.
packing (29) from both seal chambers on faceplate. If pump is equipped with mechanical
seals, refer to the seal instructions that were shipped with the pump. Also, reference Page
39 for additional packing information.
i. Loosen Tuffseal set screws that lock the cartridge seal’s collar onto the shaft. Also, reference
Page 40 for additional Tuffseal information.
on the housing. Thus, when the shafts are pulled out of this area the gland will not fall off.
Allow it to hang loosely on the studs. Also, reference Page 41 for additional mechanical seal
information.
10. Remove six bearing hex head bolts (12).
11. Remove the two bearing covers (14).
12. Remove the two faceplate bearing locknuts (15).
13. Slide impeller and shaft assembly out through the fluid chamber side of faceplate.
14. Remove the two ball bearings (17) from the bearing bridge on faceplate.
15. Check condition of lip seals (18) and replace if required.
16. Remove the two setscrews (11) from each impeller hub.
17. Press shafts through impellers by placing impeller and shaft assembly in press with threaded stub
shaft up.
18. Remove woodruff impeller keys.
v 1.5 Page 22 of 46 6.10.08

Reassembly:
1a. Install impellers onto shafts [For non-galling impellers (ductile iron)]
i. Apply lubricant to shaft end on which impeller fits (White lead is recommended).
ii. Slip impeller on shaft from the threaded stub shaft end.
iii. Install stainless steel woodruff impeller key.
iv. Align keyway in impeller with woodruff impeller key.
v. Press impeller into proper position, and install setscrews as tight as possible. The
dimensions shown below are given from the shoulder on the shaft to the nearest flat face on
the hub of the impeller.
Pump Size Impeller Location (inches)

30A 3.949 – 3.960
2A & 3A 4.709 – 4.720
70A & 120A 5.677 – 5.690
330 6.942 – 6.955
WARNING WARNING
1b. Install impellers onto shafts [For galling impellers (stainless steel)]
i. Impellers must be shrunk on the shafts, due to galling properties of the material.
ii. Heat impellers to 500-550°F for 1 ½ -2 hours.
iii. Quickly assemble shaft and impeller with keys in place into proper position according to the
dimensions from above.
iv. Allow cooling.
2. Install lip seals (18) in faceplate (22), in bottom of bearing bores on bearing bridge (19).
3. Install faceplate bearings (17) in bearing bores. Before installation, pack bearings with grease.
i. Insert packing (29) and glands (30) in seal chambers on faceplate. Also, reference Page 39
for additional packing information.
i. Install Tuffseals onto impeller stuffing boxes. Use the gland washers (45) and nuts (32) to
hand tighten the seal glands to the stuffing boxes. Do not fully tighten the nuts. Also,
i. Press in the stationary seal seat into the mechanical seal gland if replacing the seal or re-use
the existing one.
ii. Have the seal bodies and seal glands nearby as those will have to be slipped onto the shafts
as one is assembling the shafts through the impeller faceplate.
iii. Loosen the pipe plugs (24) so one will have access to the mechanical seal set screws in
order to set the correct working height of the seal. Also, reference Page 41 for additional
5. Insert impeller and shaft assemblies, threaded portion first, through stuffing box,
packing/mechanical seal body and seat, Tuffseals, seal gland, and inner race of faceplate
bearing. Secure assemblies in this position by tightening the faceplate bearing lock nuts (15). V-
rings (25) should also be installed while inserting the shafts. Be aware that the V-rings need to
be slid onto the shafts because of their snug fit.
6. Insert bearing cover (14) in place and tighten bearing hex head bolts (12). The impeller and shaft
assemblies are now secure in the faceplate.
v 1.5 Page 23 of 46 6.10.08

7. Check the clearance with a feeler gauge, between the machine face of the faceplate and the flat
surface on the lobe of the impeller. This setting clearance will vary with the material of
construction and pumping temperature. See chart below for the proper setting clearance. This
clearance is checked by revolving the impeller and shaft 360°, while checking the clearance at
multiple positions. All other clearances are automatically set if this clearance is correct.
Chamber Clearances:
Faceplate gaskets compress to approximately .003 - .004 inches when pump bolts are tightened. For
impeller assembly settings and resultant clearances, see below.
A B
MODEL RESULTING SIDE D
IMPELLER C
MATERIAL CLEARANCE RESULTING
SETTING ON RADII
CLEARANCES (OPPOSITE SIDE) PASS OVER
(SIDE)
MIN. MAX. MIN. MAX. MIN. MAX. MIN. MAX.
Model: 30A
Non-Gall Standard .0010 .0015 * .0040 .0020 .0035 .0005 .0035
Hot .0030 .0035 .0035 .0080 .0050 .0065 .0015 .0045
Gall Standard .0035 .0040 .0040 .0085 .0050 .0065 .0025 .0055
Hot .0065 .0070 .0070 .0115 .0080 .0095 .0045 .0075
Models: 2A, 3A, 70A, 120A
Non-Gall Standard .0020 .0025 .0025 .0080 .0040 .0060 .0005 .0045
Hot .0060 .0065 .0065 .0120 .0080 .0100 .0035 .0075
Gall Standard .0065 .0070 .0070 .0125 .0080 .0100 .0035 .0075
Hot .0105 .0115 .0105 .0165 .0120 .0140 .0060 .0110
Model: 330
Hot .0090 .0100 .0090 .0150 .0110 .0130 .0050 .0110
Gall Standard .0105 .0115 .0105 .0165 .0120 .0140 .0060 .0120
Hot .0155 .0165 .0155 .0215 .0170 .0190 .0100 .0160
C
SINGLE LOBE
IMPELLER * Check to ensure that pump
A
B still rotates freely
HOUSING
FACEPLATE
MATING IMPELLER
8. If the impellers are properly set on the shaft to dimensions from step 1, then the initial setting
clearance will always be too large. Thus, to move the impeller to the proper setting, add shims
between bottom of bearing bore and the bearing outer race.
The following shims are available:
Red .002‖
Blue .005‖
Pink .015‖
9. Grease faceplate bearings thru fittings on bearing caps.
10. For the remaining reassembly procedure, refer to steps 1 - 16 in Minor Reassembly Instructions.
v 1.5 Page 24 of 46 6.10.08

7 8 9 14 12 10 11 13 16 17 18 10
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22
3 21
5
15 20
6 35
34 19
23
37
25
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27 28 29 10 32 33 30 31 36 38 39 40 41 42 43
General Parts List For Model 600 Pumps (Models Starting w/ O1)

1 Lock Nut 2 26 Bearing Cover 2
2 Lock Washer 2 27 Ball Bearing 2
3 Driven Shaft (CI) 1 28 Set Screw 6
(SS) 29 Bearing Carrier 2
4 Impeller Key (CI) 2 30 Nut (CI) 8
(SS) (SS)
5 Set Screw 4 31 Stud 8
6 Impellers (CI) S.L. 2 32 Shim ----------------.002” As Req.
(CI) D.L. .005” As Req.
(SS) S.L. .015” As Req.
(SS) D.L. 33 Faceplate (CI) 1
7 Drive Shaft (CI) 1 (SS)
(SS) 34 Pipe Plug (CI) 8
8 Gear Key 2 (SS)
9 Key 1 35 Housing Gasket 1
10 Lip Seal 5 36 Packing 4 sets
11 Bearing Spacer 2 37 Cap Screw 4
12 Eye Bolt 1 38 Dowel Pin 2
13 Roller Bearing 2 39 Housing Bushings 2
14 Timing Gear 2 (CI) DU Bushing
15 Dowel Pin 2 (SS) Carbon Bushing
16 Nametag 1 40 Impeller Housing (CI) 1
17 Drive Screw 2 (SS)
18 Vented Pipe Plug 1 41 Cap Screw 4
19 Gear Case 1 42 Packing Gland (CI) 4
20 Gear Case Gasket 1 Split Glands for (SS) 8
21 Hex Head Bolt 10 43 V-Ring 4
22 Gear Case Cover 1
23 Pipe Plug 2
24 Grease Fitting 2
25 Hex Head Bolt 16
Note:
v 1.5 Page 26 of 46 6.10.08

7 8 9 14 12 10 11 13 16 17 18 10
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22
5
21
6 15
35 34 20
37 19
23
25
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25
34
26
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General Parts List For Model 600 Pumps (Models Starting w/ O5)

3 Driven Shaft 1 28 Set Screw 6
(Armco 17-4PH) 29 Bearing Carrier 2
(SS) (SS)
(CI) D.L. .005” As Req.
(SS) S.L. .015” As Req.
7 Drive Shaft 1 (SS)
(Armco 17-4PH) 34 Pipe Plug (CI) 8
8 Gear Key 2 (SS)
9 Key 1 35 Gore-Tex Gasket 1
10 Lip Seal 5 36 Packing 4 sets
19 Gear Case 1 42 Packing Gland (CI) 4
20 Gear Case Gasket 1 Split Glands for (SS) 8
23 Pipe Plug 2
24 Grease Fitting 2
25 Hex Head Bolt 16
Note:
v 1.5 Page 28 of 46 6.10.08

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3
21
5 15
6 35 34 20
37 23 19
25
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General Parts List For Model 600 Pumps (Models Starting w/ O5 & Tuffseals)

(SS) (SS)
(CI) D.L. .005” As Req.
(SS) S.L. .015” As Req.
8 Gear Key 2 (SS)
10 Lip Seal 5 36 Tuffseal 4
19 Gear Case 1 42 V-Ring 4
20 Gear Case Gasket 1
21 Hex Head Bolt 10
23 Pipe Plug 2
24 Grease Fitting 2
25 Hex Head Bolt 16
Note:
v 1.5 Page 30 of 46 6.10.08

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5 21
15
6
35 34 20
37 23 19
25
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27 28 29 10 32 33 30 31 38 36 39 40 41 44 42 43
General Parts List For Model 600 Pumps (Models Starting w/ O5 & Mech. Seals)

(SS) (SS)
(CI) D.L. .005” As Req.
(SS) S.L. .015” As Req.
8 Gear Key 2 (SS)
10 Lip Seal 5 36 Mechanical Seals 4
19 Gear Case 1 42 Mech. Seal Gland (CI) 4
20 Gear Case Gasket 1 (SS) 4
22 Gear Case Cover 1 44 Seal Gland Gasket 4
23 Pipe Plug 2
24 Grease Fitting 2
25 Hex Head Bolt 16
Note:
v 1.5 Page 32 of 46 6.10.08

WARNING WARNING
Disassembly & Reassembly Instructions for Model 600 Pumps
Minor Disassembly For Fluid Chamber Inspection:
1. Remove all burrs on drive shaft with a mill file or emery paper. Also check for deposit of paint.
Special care should be taken around the keyway and beveled corner on the drive shaft. These
two areas are normally where burrs appear. Burrs or paint will cause an obstruction in the
bushing area.
2. Drain oil from gear case by removing lower drainpipe plug. Remove cap screws (23) on face of
gear case cover.
3. Remove gear case cover (22) by sliding over shafts.
4. If the timing gears (14) are a slip fit on the shafts. Mark gears so that in reassembly the gears
may be remounted on the shafts from which they were removed. Remove the gears by loosening
the setscrews. There are two in each gear. Then slide gears off drive end of shaft. If gear keys
are sheared a gear puller may be required. Remove two woodruff gear keys (8).
5. If interference fitted (IF) timing gears (14) are furnished. Mark gears so that in reassembly
the gears may be remounted on the shafts from which they were removed. IF gears do not have
setscrews. First attempt to remove them can be can be made with a standard gear puller. Check
that the gears have the correct timing marks before removal. If necessary, mark them again. If the
gear puller was not successful in removing the gears, heat the gear OD with a torch and use a
hydraulic jack to remove the gears.
WARNING WARNING
v 1.5 Page 33 of 46 6.10.08

packing (36) from both seal chambers in the impeller housing. If pump is equipped with
mechanical seals, see below for general instructions and refer to the seal instructions that
were shipped with the pump. Also, reference Page 39 for additional packing information.
i. Loosen Tuffseal set screws that lock the cartridge seal’s collar onto the shaft, on the impeller
housing side. Also, reference Page 40 for additional Tuffseal information.
on the housing. Thus, when the shafts are pulled out of this area when removing the
faceplate assembly the gland will not fall off. Allow it to hang loosely on the studs. Also,
reference Page 41 for additional mechanical seal information.
7. Remove hex head bolts (25) on outboard side of faceplate. Make note on which side the drive
shaft is located for reassembly. Remove entire faceplate by sliding away from impeller housing. .
CAUTION: Faceplate assembly will be heavy and not balanced. Use proper lifting methods.
This assembly includes the impellers and shafts installed in the faceplate. CAUTION: Do not
disturb the bearing covers (26) on the bearing bridge on the faceplate. These covers hold the
adjustment of clearance of the impeller in relation to the fluid chamber.
If further disassembly is required, refer to major disassembly instructions.
Fluid Chamber Check Points:
Procedure No. 1 - Check for twisted shaft
1. Place faceplate group upright in vise. Caution: Use soft jaws to prevent damage to the gasket
seal surfaces. Tighten jaws on sides of bearing bridge.
2. Install carbon steel gear keys on an angle. Angle is to hold gears from sliding down on shaft.
3. Slide proper timing gear on drive shaft, revolving shaft to align key with gear keyway, taking
precautions that the timing marks are face out and aligned. There are two punch marks
appearing on the gear on the drive shaft and one punch mark on the mating tooth on the driven
shaft.
4. Turn impellers to the position shown below. If the dimension X is the same as dimension Y, then
there is no shaft damage. If there is a variation, then the shaft is twisted or the impeller keys may
be sheared. Disassemble in accordance with major disassembly instructions. If the impeller keys
are sheared, install new keys and recheck for twisted shaft.
v 1.5 Page 34 of 46 6.10.08

Procedure No. 2 - Install new gears
1. Place faceplate group in vise and install woodruff keys as in Procedure No. 1.
2. Slide gear on driven shaft, aligning keyway of gear with woodruff key on shaft.
3. Position impellers as shown in the sketch in Procedure No. 1 with dimension X the same as
dimension Y.
4. Slide timing gear on drive shaft and align keyway in gear with woodruff key in shaft and mesh
gears.
5. Recheck dimension X and dimension Y to be certain that they are the same.
6. Mark gears as indicated in Procedure No. 1.
7. Slide gears off shafts and follow minor reassembly instructions.
Procedure No. 3 - Install new bushings
1. Disassemble in accordance with minor disassembly instructions.

2. Press worn bushing from impeller housing and gear case.
3. Press new bushings in impeller housing.
4. Press bronze bushings in gear case.
5. Remove expansion plug in gear case cover.
6. Press out worn bushings and press new bushings in gear case cover. Caution: If impeller housing
bushing is steel backed PTFE, do not ream.
7. Check gear case lip seals and bearings for damage. Replace parts as necessary.
Reassemble In Accordance With Minor Reassembly Instructions:
1. Apply grease to gasket seal surface on impeller housing. Then press impeller-housing gasket in
place. Grease is used to hold gasket in position.
i. Place packing glands (42) in seal chambers of housing (40). Also, reference Page 39 for
additional packing information.
i. Make sure the Tuffseal on the impeller housing side is ready to accept the shafts and that the
collar set screws are unscrewed enough so that the shafts can slide through the collars
easily. Also, reference Page 40 for additional Tuffseal information.
i. Make sure the mechanical seal bodies in the impeller housing stuffing boxes are ready to
accept the shafts and that the seal set screws are unscrewed enough so that the shafts can
slide through the seals easily. Also, reference Page 41 for additional mechanical seal
information.
3. After checking for burrs, insert shafts, through housing bushing, packing glands/mechanical
seals/Tuffseals and gear case bushings. V-rings (43) should also be installed while inserting the
shafts. Be aware that the V-rings need to be slid onto the shafts because of their snug fit. Note:
Insert drive shaft on same side as when disassembled.
4. Tighten cap screws, which hold faceplate in place.
5. Slip fit timing gears. Install carbon steel gear keys in shaft keyways. Slip proper timing gear on
driven shaft. Then slip timing gear on drive shaft, revolving shaft to align woodruff key with gear
keyway, taking precautions that the timing marks are face out and aligned. These marks are two
center punch marks on the gear on the drive shaft and one center punch mark on the mating
tooth cavity. Then turn pump drive shaft over several times to be certain that there is no
interference from being out of time. Tighten setscrews on shaft. Then install locking setscrew.
6. Interference fitted timing gears. Make sure that gears are properly marked with the timing
marks and that the bores and keyways are free of burrs. Repair as necessary. Heat the gears to
500°F-550°F in an oven for 40 minutes. Add keys to the drive and driven shafts.
v 1.5 Page 35 of 46 6.10.08

WARNING WARNING
7. Install the timing gear on the driven shaft first, making sure that the timing marks are facing
outward. Assure that the driven gear has cooled before installing the drive gear. Match the timing
gears and install the drive gear. Rotate the shafts after the gear cools to assure the correct
timing of the impellers.
8. If timing is correct, apply grease to gasket seal surface on gear case. Press gear case gasket in
place.
9. Slide gear case cover over shafts, being certain that drive shaft bore in cover is properly
positioned in relation to drive shaft. Then tighten cap screws holding gear case cover in place.
CAUTION: Take care in slipping lip of oil seal over drive shaft. If proper care is not taken, the lip
will be damaged and oil leakage will result.
i. Install new packing in seal chambers and tighten packing gland nuts to finger tightness. If
pump is equipped with mechanical seals, install them according to the seal instructions and
reference 12c for general instructions. Also, reference Page 39 for additional packing
information.
i. Use the seal spacers to set the right collar location. After setting the end clearances, tighten
the gland nuts and then collar set screws to lock the seal collar onto the shaft. Finally, turn
the spacers away from the collar so they will not interfere with it during operation. Also,
i. Position the mechanical seal body axially on the shaft using the previous mark that was made
during disassembly.
ii. After setting the end clearances, tighten the seal set screws to the shaft.
iii. Install the mechanical seal gland back into the impeller housing stuffing box and tighten the
gland nuts (32). Re-install the pipe plugs (24). Also, reference Page 41 for additional
11. Install drainpipe plug. Remove oil level plug. Fill gear case with lube oil (see lube chart on page
9) until oil comes out oil level hole. Then install and tighten fill plug and oil level plug.
12. Spin the assembled pump several times to be certain that there is no interference from incorrect
timing. If no interference is apparent, the pump is ready to be put back in service.
Major Disassembly Instructions:
The first seven steps are the same as in the minor disassembly procedure. The major disassembly
involves the disassembly of the faceplate group.
8. Place faceplate group in a vise. CAUTION: Use soft vise jaws to prevent damage to gasket seal
surface.
packing (36) from both seal chambers on faceplate. If pump is equipped with mechanical
seals, refer to the seal instructions that were shipped with the pump. Also, reference Page
39 for additional packing information.
i. Loosen Tuffseal set screws that lock the cartridge seal’s collar onto the shaft. Also, reference
v 1.5 Page 36 of 46 6.10.08

on the housing. Thus, when the shafts are pulled out of this area the gland will not fall off.
Allow it to hang loosely on the studs. Also, reference Page 41 for additional mechanical seal
information.
10. Remove six hex head bolts (25). Remove bearing covers (26). Press tines of lock washers (2)
out of grooves on lock nut (1). Remove lock nut.
11. Remove bearing carrier (29) and bearing (27). CAUTION: Note the shims that are placed
between bearing carrier (29) and faceplate (33). If shafts and impellers are not replaced, these
shims must be returned to the same position from which they were removed. Now slide impeller
and shaft assembly out through the fluid chamber side of faceplate.
12. Remove the two double row faceplate ball bearings (27) from the bearing carriers (29). Then
remove lip seals (10) and check condition. Replace if required.
13. If the shaft or impeller needs to be replaced, remove two set screws (5) from each impeller hub.
Then press shafts through impellers by placing impeller and shaft assembly in press with
threaded stub shaft up. Remove impeller keys (4).
Reassembly:
1a. Install impellers onto shafts [For non-galling impellers (ductile iron)]
i. Apply lubricant to shaft end on which impeller fits (White lead is recommended).
ii. Slip impeller on shaft from the threaded stub shaft end.
iii. Install steel woodruff impeller key.
iv. Align keyway in impeller with woodruff impeller key.
v. Press impeller into proper position, and install setscrews as tight as possible. The
dimensions shown below are given from the shoulder on the shaft to the nearest flat face on
the hub of the impeller.
Pump Size Impeller Location (inches)

600 8.018 – 8.033
WARNING WARNING
1b. Install impellers onto shafts [For galling impellers (stainless steel)]
i. Impellers must be shrunk on the shafts, due to galling properties of the material.
ii. Heat impellers to 500-550°F for 1 ½ -2 hours.
iii. Quickly assemble shaft and impeller with keys in place into proper position according to the
dimensions from above.
iv. Allow cooling.
2. Install lip seals (10) in faceplate (23), in bottom of bearing bores on bearing bridge.
3. Install faceplate bearings (27) in bearing bores. Before installation, pack bearings with grease.
i. Insert packing (36) and glands (42) in seal chambers on faceplate. Also, reference Page 39
for additional packing information.
i. Install Tuffseals onto impeller stuffing boxes. Use the gland washers and nuts (30) to hand
tighten the seal glands to the stuffing boxes. Do not fully tighten the nuts. Also, reference
i. Press in the stationary seal seat into the mechanical seal gland if replacing the seal or re-use
the existing one.
v 1.5 Page 37 of 46 6.10.08

ii.
Have the seal bodies and seal glands nearby as those will have to be slipped onto the shafts
as one is assembling the shafts through the impeller faceplate.
iii. Loosen the pipe plugs (34) so one will have access to the mechanical seal set screws in
order to set the correct working height of the seal. Also, reference Page 41 for additional
5. Insert impeller and shaft assemblies, threaded portion first, through stuffing box,
packing/mechanical seal body and seat, Tuffseals, seal gland and inner race of faceplate bearing.
V-rings should also be installed while inserting the shafts. Be aware that the V-rings (43) need to
be slid onto the shafts because of their snug fit. Secure assemblies in this position by tightening
the faceplate bearing lock nuts (1).
6. Insert bearing covers (26) in place and tighten bearing hex head bolts (25). The impeller and
shaft assemblies are now secure in the faceplate.
7. Check the clearance with a feeler gauge, between the machine face of the faceplate and the flat
surface on the lobe of the impeller. This setting clearance will vary with the material of
construction and pumping temperature. See chart below for the proper setting clearance. This
clearance is checked by revolving the impeller and shaft 360° while checking the clearance at
multiple positions. All other clearances are automatically set if this clearance is correct.
Chamber Clearances:
Faceplate gaskets compressed to approximately .003 - .004 inches when pump bolts are tightened.
Impeller assembly settings and resultant clearances see below.
A B
MODEL RESULTING SIDE D
IMPELLER C
MATERIAL CLEARANCE RESULTING
SETTING ON RADII
CLEARANCES (OPPOSITE SIDE) PASS OVER
(SIDE)
MIN. MAX. MIN. MAX. MIN. MAX. MIN. MAX.
Model: 600
Hot .0120 .0130 .0120 .0180 .0140 .0160 .0070 .0130
Gall Standard .0185 .0195 .0185 .0245 .0200 .0220 .0130 .0190
Hot .0245 .0255 .0245 .0305 .0260 .0280 .0170 .0230
C
SINGLE LOBE
IMPELLER * Check to ensure that pump
A
B still rotates freely
HOUSING
FACEPLATE
MATING IMPELLER
8. If the impellers are properly set on the shaft to dimensions from step 1, then the initial setting
clearance will always be too large. Thus, to move the impeller to the proper setting, add shims
between bottom of bearing bore and the bearing outer race.
The following shims are available:
Red .002‖
Blue .005‖
Pink .015‖
9. Grease faceplate bearings thru fittings on bearing caps.
10. For the remaining reassembly procedure, refer to steps 1 - 16 in Minor Reassembly Instructions.
v 1.5 Page 38 of 46 6.10.08

Packings:
Installing Packings in Pumps:
1. Remove all old packing using a packing hook. Clean stuffing box and shaft thoroughly and
examine shaft for wear or scoring. Check bearings for wear as this can cause an eccentric shaft
rotation resulting in excessive leakage. Packings will not act as a bearing. If shaft surface is
worn, replace shaft or have seal surface area resurfaced.
2. Be certain the proper size packing is used. The following packing sizes will apply:
Pump Model Packing Size Shaft Diameter No. of Rings

30A 1/4‖ Square 1‖ 4
2A & 3A 1/4‖ Square 1-3/8‖ 4
70A & 120A 7/16‖ Square 1-7/8‖ 6
330 1/2‖ Square 2-1/4‖ 6
600 1/2‖ Square 2-1/2‖ 6
3. Always cut packings into separate rings. Never coil around shaft. (standard factory packings are
pre-cut and pre-formed) If bulk packing is used cut each ring on a mandrel the same size as the
pump shaft. Try rings in stuffing box to be certain that each ring fills the seal chamber and that
there is no gap between packing joints.
4. Install one ring at a time, seating each ring independently. Use clean oil to lubricate shaft and
inside of stuffing box. Joints should be staggered and kept at least 90° apart. Each individual
ring should be firmly seated with a tamping tool. Never depend entirely on the gland to seat a set
of packings. This practice will jam the last rings installed but leave the front rings loose. The
result is excessive and rapid wear.
5. After last ring is installed, tighten gland nuts finger tight. Then start pump and take up nuts until
leakage is decreased. Stopping leakage at this point will cause packing to burn. If temperature
rises in seal area, back off on packing nuts as this indicates excessive gland pressure.
6. Allow packing to leak freely for at least one hour when starting up a newly packed pump. Take
up gland nuts gradually, 1/16 turn every 5-10 minutes, until leakage stabilizes at about 3-5 drops
per minute. If temperature in seal area increases, back off and start over.
Note:
- Replace packing when leakage cannot be controlled by further take-up of gland.
- Test results indicate that 70% of the wear occurs on the first two rings of packing nearest the
gland. Rings next to the gland work the hardest. The rings in the bottom of the stuffing box serve
to throttle some fluid pressure. On abrasive service the bottom ring takes most of the beating.
Therefore, this ring should be a firm ring.
How to Pack for Abrasive Liquids:
As used here ―Abrasives‖ is a broad term intended to cover the problem of packing against
slurries, congealing liquids and the likes. They cause the greatest damage to equipment, and present
difficulties for packing. In general, this involves flush, purges and temperature control. Hard facing on the
shaft seal surfaces, such as stellite or ceramic, are also recommended.
When pumping slurries and abrasives an external source of clear or otherwise suitable liquid
must be force fed at a pressure higher than that existing in the stuffing box. This differential pressure is in
the area of 10-25 psi.
Suspended Solids:
Solids which are suspended in liquids and which are an inherent part of their structure would
include starch, clay slurry, muddy water and other similar slurries. This is best handled by an external
flush of clear liquid through a lantern ring as shown. This arrangement will result in a small amount of
product dilution and is controlled by the differential pressure in the seal chamber.
v 1.5 Page 39 of 46 6.10.08

Packing with Internal Flush
How To Pack For Congealing Liquids:
These liquids congeal either because of a change in temperature or as a result of drying out after
exposure to air. Clay coatings and latex fall into both categories. A good rule is to keep the fluid moving
before congealing can take place. Control with cooling or heat and/or by flush or purge.
Some products harden to a solid state when exposed to air. Clay coatings, latex and sugars are
examples. An effective flush is shown. Note that this type of flush does not enter the product, but only
mixes with the product leakage. This arrangement also tends to serve as cooling medium for the seal
chamber.
Packing with External Flush
Tuthill Tuffseal® Cartridge Seals:
Installing Tuffseals in Pumps:
1. Once pump is fully disassembled (shafts are removed from the impeller housing and faceplate)
one can clean stuffing box and shafts thoroughly and examine shaft for wear or scoring. Check
bearings for wear as this can cause an eccentric shaft rotation resulting in excessive leakage. If
shaft surface is worn, replace shaft or have seal surface area resurfaced.
2. Install new Tuffseal Cartridge seals to the impeller housing and faceplate by fitting the studs into
the seal gland slots. Then install the washers and nuts to hold the seal gland onto the stuffing
box. These nuts should be tightened finger tight so that the seal assembly can move when the
shafts are being installed.
3. During re-assembly, lubricate both of the seal’s O-rings to and make sure the shafts are guided
through the Tuffseal collar. Apply even pressure when pushing the shaft through the seal as to
not damage the collar O-rings.
4. Once the entire pump is re-assembled, make sure the collar shoulder is seated against the seal
spacers.
5. Tighten the seal gland nuts to secure the Tuffseal to the stuffing box.
6. After the pump’s end clearance is set, then tighten the collar setscrews evenly to the shaft.
7. Rotate the spacers away from the collar so that they will not rub against any rotating component
when the seal is operating.
v 1.5 Page 40 of 46 6.10.08

Mechanical Seals (General):
Installing Mechanical Seals in Pumps:
1. Once pump is fully disassembled (shafts are removed from the impeller housing and faceplate)
one can clean stuffing box and shafts thoroughly and examine shaft for wear or scoring. Check
bearings for wear as this can cause an eccentric shaft rotation resulting in excessive leakage. If
shaft surface is worn, replace shaft or have seal surface area resurfaced.
2. Install new stationary seal seat into the mechanical seal gland. Use a seal lubricant to aid in
pressing the seat into the gland. Do not scratch or score the seal face during this process as it
will result in a leak.
3. During re-assembly, make sure the mechanical seals and the glands are guided through the
shafts as they are installed. Apply even pressure when pushing the shaft through the seal as to
not damage the O-rings or seal bellows.
4. Once the entire pump is re-assembled, and the correct end clearance is set, reference the correct
working length of the seal.
5. Mark the shaft, through the stuffing box access port, where the correct working length would be
on the shaft.
6. Move the seal body to that mark and tighten the seal setscrews. This sets the correct working
height of the mechanical seal. Please reference the seal’s manual for the correct working height.
7. Install the seal gland and seal gland gasket to the stuffing box.
8. Tighten the nuts to the seal gland.
v 1.5 Page 41 of 46 6.10.08

Torque For Shaft Locknuts
Industrial Models Torque (ft-lbs.)

30A 60 – 65
2A & 3A 75 – 80
70A, 120A, 330, & 600 120 – 125
Torque For Faceplate Bolts
Faceplate Applied
Pump Screw Type of
Qty. & Torque
Model Description Metal
Appearance (ft-lbs)
½" Hex Head, 1 ½" LG. P104-1H Note 1 10 -- 70 - 75

600
½" Socket Head, 1 ½" LG. P105-74 Note 2 4 -- 70 - 75
1/2” Socket Head, 11/8” LG P104-1S4 Note 3 14-- 30 - 35
½" Hex Head, 1 ¼ " LG. P104-4H Note 1 8 -- 70 - 75

330
½" Socket Head, 1 ¼ " LG. P105-57 Note 2 4 -- 70 - 75
70 - 75
½" Hex Head, 1 ¼" LG. P104-4H Note 1 13 --
70A, 120A 70 - 75
½" Hex Head, 1" LG. P104-2H Note 1 1 --
11 - 14
¼" Socket Head, 1 ½" LG. P105-78 Note 2 4 --
70 - 75
2A, 3A
70 - 75
3/8" Socket Head, 1" LG. P105-66 Note 2 4 -- 45 -50

30A
3/8" Socket Head, 3 ½" LG. P105-79 Note 2 2 -- 45 - 50
1. SAE grade 5 steel (Min. tensile strength of 105,000 PSI heat-treated medium carbon).
2. High carbon alloy, quenched and tempered (Min. tensile strength of 160,000 PSI).
3. Grade 316 stainless steel.
v 1.5 Page 42 of 46 6.10.08

Serial Number Location
The serial number will be located on the pump nameplate. In addition, the serial number may be
located on the impeller housing top port. Please furnish this number when ordering parts. Pumps with
the built-in pressure relief valve must have a top suction port.
v 1.5 Page 43 of 46 6.10.08

Common Causes of Pump Problems
Symptoms
Loses Prime
Much Power
Starts, Then
Takes Too
Excessive
Excessive
Low Flow
Leakage
Fails to
Suggested
Gland
Pump
Noisy
Wear
Heat
Possible Causes
Solutions
   Suction line high for

vapor pressure of liquid
Reduce vacuum
requirements
   Liquid too viscous for

pump speed
Reduce pump
speed
   Air leakage in suction

piping
Tighten and seal all
joints
Lengthen suction
  Suction pipe not
immersed in liquid
pipe or add liquid to
supply tank
Suction strainer
  clogged or of
insufficient area
Clean strainer or
use larger size
Re-align. Check
     Misalignment between
pump and driver
coupling alignment
with dial indicator
    Rotating elements
binding
Disassemble and
inspect
Disassemble pipe
    Pipe strain on pump
casing
and re-align before
reassembling
  Relief valve chattering

Check setting and
valve seating
Check for
    Excessive system
pressure
obstructions in
discharge line.
   Stuffing box packed too

tightly
Repack and adjust
 Pump speed to low

Check pump
impeller speed
Have pump
  Pump parts worn reconditioned or
replace worn parts
Check discharge
  Obstruction in
discharge line
piping and valves
for obstruction
 Wrong direction of
rotation
Reverse motor
  Suction line sized too

small
Increase suction
piping size
 Torque control coupling

not adjusted
Readjust coupling
v 1.5 Page 44 of 46 6.10.08

Troubleshooting
1. Problem: No fluid is delivered.
a. Power is not on.

b. Net positive suction head available (NPSHa) is lower than required for the vapor pressure of the
liquid pumped. You should calculate NPSHa and redesign piping, if necessary.
c. There are leaks in suction line.
d. Direction of shaft rotation is incorrect.
e. Relief valve setting is too low (if the pump is equipped with a relief valve). Liquid is discharging
through the by-pass port.
2. Problem: Capacity is too low.
a. There are air leaks in suction line.

b. Suction losses are too high. The suction lift is too great or the suction line is too small or too long.
This can be detected by installing a vacuum gauge directly at the pump suction. The maximum
vacuum at the pump suction should never exceed 15‖ of mercury. Vaporization caused by higher
vacuums will generally result in capacity drop-off. Redesign suction conditions.
c. Pump speed is too slow.
d. Strainer is too small or obstructed.
e. Suction pipe or port is not immersed in liquid deep enough.
f. Piping is improperly installed permitting an air pocket to form in the pump.
g. Increased clearances or wear in the pump will sometimes cause the pump to deliver an
insufficient supply of liquid.
3. Problem: Pump works spasmodically.
a. Leaky suction lines.

b. Suction conditions vary.
c. Air or vapor is in the liquid.
4. Problem: Excessive power draw.
a. Pressure is too high.

b. Liquid is more viscous than originally expected.
c. Suction or discharge line is obstructed.
d. There is insufficient horsepower.
e. There are mechanical defects:
i. Drive shaft and pump are misaligned.
ii. Pump is binding due to incorrect clearance setting.
iii. Pump shaft is bent.
iv. There is misalignment within pump due to bad piping or poor installation, causing strain
or distortion.
5. Problem: Pump is noisy.
a. Pump is cavitating due to inadequate suction conditions.

b. There is misalignment of coupling.
c. Coupling is set too close to pump.
d. There is vibration of the pump due to a worn or bent shaft.
e. There are air leaks on suction side of pump or air entrainment in the fluid.
6. Problem: Pump leaks.
a. Bolts need tightening, allowing gaskets or O-rings to leak.

b. Gaskets or O-rings are damaged.
Note: Packings are designed to leak. Leakage should be at a rate that will prevent excessive heating on
the bracket at the packing area.
v 1.5 Page 45 of 46 6.10.08

Material Returns
If it becomes necessary to return a pump to the factory, a Return Goods Authorization (RGA) must be
obtained from either your local Authorized Distributor or our Alsip plant. No RGA can be issued until a
completed Material Safety Data Sheet (MSDS) has been forwarded to our Alsip plant and return of the
pump has been approved.
 Tuthill pumps are precision-built and must be handled with care.

 Pumps must be drained of all fluid and the ports plugged to prevent foreign material from getting into
the pump.
 Pumps must be packaged securely to prevent damage while in transit.
WARRANTY
Tuthill Pump Group warrants its products against defective material and workmanship for 90 days
from the date of startup or one year from date of shipment from Tuthill's plant, whichever comes first.
This warranty does not include products damaged by tampering, improper installation, abuse, or wear.
Nor does it cover consequential damages, or other losses due to pump failure.
Because of the unpredictable nature of fluids encountered, pumps are not warranted for any
specific life.
Contact Information
If additional information is required to facilitate operation or maintenance, contact the authorized

Tuthill distributor shown below. Information on Tuthill contacts can also be obtained at
www.tuthillpump.com.
European Contact Info:
Tuthill Pump Group

Manners Industrial Estate
Ilkeston, Derbyshire DE7 8YA
England
tuthilluk@tuthill.com
North America Contact Info:
Tuthill Pump Group

12500 South Pulaski Road
Alsip, Illinois 60803
U.S.A.
www.tuthillpump.com.
v 1.5 Page 46 of 46 6.10.08

Installation and Service Instructions HD Series Pumps Industrial Duty Models

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Installation and Service Instructions HD Series Pumps Industrial Duty Models

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Service Instruction No.

INSTALLATION AND SERVICE

v 1.5 Page 1 of 46 6.10.08

Read Manual before operating or working on a Tuthill HD pump.

v 1.5 Page 2 of 46 6.10.08

Service Manual # 71 for the HD Series pumps is available at www.tuthillpump.com

Pump needs to be earthed separately to avoid a buildup of electro-static charge.

v 1.5 Page 3 of 46 6.10.08

Here’s how it works:

Material of Max. Max. Capacity Max. Pressure Weight Port Size

30A 450 24.7 93 150 10.3 100 45 Same As Above

v 1.5 Page 4 of 46 6.10.08

O5 – INDUSTRIAL O2-STANDARD DUTY O4-STANDARD DUTY

04 – 316 Stainless Steel (O1, O4 & O5 Models)

v 1.5 Page 5 of 46 6.10.08

Class 1 Clearance Impellers

High Temp. Carbon Bushings

Gore-Tex Rope Gaskets

Viton Oil Seals for Faceplate

PTFE Oil Seals for Faceplate

High Temperature APG 250

Standard DU Bushings for Ductile Iron Pumps

Pump needs to be earthed separately to avoid a buildup of electro-static charge.

Pumps should be filled with liquid at installation.

v 1.5 Page 7 of 46 6.10.08

Never operate the pumps without all the guards in place.

Pumps with packing will require periodic adjustment.

v 1.5 Page 8 of 46 6.10.08

Gear Case Bearings:

Lubrication Instructions For Tuthill Process Pumps

Oil specifications are as follow:

Viscosity at 100F: 816 SSU Viscosity at 212F: 86 SSU

Grease specifications are as follows:

Lithium Base N.L.G.I. #2

Gearcase First Oil Subsequent Total Grease Capacity

Oil Specification: Lubriplate APG 250 or equal

v 1.5 Page 9 of 46 6.10.08

v 1.5 Page 10 of 46 6.10.08

Item # Description Qty Item # Description Qty

v 1.5 Page 12 of 46 6.10.08

Item # Description Qty Item # Description Qty

v 1.5 Page 14 of 46 6.10.08

Item # Description Qty Item # Description Qty

v 1.5 Page 16 of 46 6.10.08

Item # Description Qty Item # Description Qty

v 1.5 Page 18 of 46 6.10.08

Minor Disassembly For Fluid Chamber Inspection:

Wear heat-resistant gloves when handling hot components.

6a. If Packing is used (reference assembly on page 13):

If further disassembly is required, refer to major disassembly instructions.

v 1.5 Page 19 of 46 6.10.08

Procedure No. 1 - Check for twisted shaft

1. Place faceplate group upright in vise.

Procedure No. 2 - Install new gears

1. Place faceplate group in vise and install keys as in Procedure No. 1.

Procedure No. 3 - Install new bushings

1. Disassemble in accordance with minor disassembly instructions.

v 1.5 Page 20 of 46 6.10.08

v 1.5 Page 21 of 46 6.10.08

8. Place faceplate group in a vise.

v 1.5 Page 22 of 46 6.10.08

Pump Size Impeller Location (inches)

Wear heat-resistant gloves when handling hot components.